aprilia saad V990 engine 8140586COVERING LETTER 1990 engine Date of the first edition: 10 - 10 - 2001 COVERING LETTER FOR RELEASE 01/2001-10 UPDATE Date of the first edition (Release 00) and of the following LIST OF THE PAGES UPDATED WITH RELEASE Releases: 0172001-10 First edition (Release 00) .. .. june 2001 Release 01 sesasnan october 2001 page# Release 0-1 -00 ot INFORMATION ON THE UPDATING OF THE MANUAL 9-2-0 ot ‘The manual must be updated every time anew “Re. 0-3-0 ot lease” is received. 0-7 -00 ot 2-3 -00 ot 2-4 -00 ot Ualand eliminate the corresponding obsolete pag: | 2” 19° 1 es (even if belonging to a previous Release). a 3 oo i The failure to update the manual and to || 3-22-00 ot eliminate the obsolete pages makes it || 4-2 -00 ot more difficult to consult the manual and || 4-26-00 ot may lead to the performance of incorrect || 4-27-00 o1 operations on the vehicle, with serious || 4-28-09 o1 consequences for the safety of the 4-29-% o1 engine, of the vehicle and of persons and | ae 3 or property. _ 4-32-00 1 4-33-00 ot 4-34-00 ot 4-35-00 ot 4-55-00 ot 5-12-00 ot 5-13-00 ot 0-2 -00 ot 0-3 -00 ot990 engine | nmmopucnioN E GENERAL pronnenen E | TECHNICAL INCORMATION: E DISASSEMBLING THE ENGINE E WORK ON THE INDIVIDUAL PARTS. E ‘reassensuncmeenane I ANALYTICAL INDEX E V990 engine 1055-1 @ 01/2001-10 1 \&] workshop manual 3) aprilia parts 8140586 pacwseovoso ——— 53] ————— 1-0INTRODUCTION ¥990 engine INTRODUCTION Pek ae 0.1 UPDATE OF RELEASE 01/2001-10 .. 0.1.1 INFORMATION ON THE UPDATING OF THE MANUAL, 0.1.2 UPDATED MANUAL GENERAL LIST 0.2 HOW TO CONSULT THE MANUAL 0.3 FOREWORD 0.4 REFERENCE MANUALS 0.4.1 VEHICLE WORKSHOP MANUALS 0.4.2 SPARE PARTS CATALOGUES 0.4.3 SPECIAL TOOL MANUALS 0.4.4 USE AND MAINTENANCE. BOOK 0.5 SAFETY WARNINGS . 0.5.1 PRECAUTIONS AND GENERAL INFORMATIONS 0.5.2 BEFORE THE DISASSEMBLY OF THE COMPONENTS 0.5.3 DISASSEMBLING THE COMPONENTS. 0.5.4 REASSEMBLING THE COMPONENTS: aoe 0.6 HOW TO USE YOUR WORKSHOP MANUAL nnn 0.6.1 ADVICE FOR CONSULTATION 0.7 ABBREVIATIONS / SYMBOLS / INITIALS - 2-00 0-3-00 0-6-0 0-6-0 0-6.00 0-6-00 0-7-0 0-7-0 . 0-8-00 Release 01/2001-10INTRODUCTION v990 engine 0.1 UPDATE OF RELEASE 01/2001-10 pagt Release pag.t Date ofthe first edition (Release 00) and ofthe folowing 4-1. -00 00 4-65 -00 Releases 4:2 -00 o1 4-65 -00 First edition (Release 00) june 2001 4-3 -00 00 5-1 +00 Release Of wo SCONeabber a0ot 424-09 09 5-2 -00 4:5 -00 00 5-3 -00 0.1.1 INFORMATION ON THE UPDATING OF THE 4-6 -00 00 5-4 -00 MANUAL 4:7 0 00 5-5 -00 The manual must be updated every time anew “Re- 4-8 - 00 5-6 0 Tease” Is recelved. 4:9 -0 00 5-7 -00 4210-00 00 8-8 -00 oe 4-11-00 00 5-9 -00 Insert the pages of the last Release in the manual |] 4-12 00 oo erty iat and eliminate the corresponding ebsolete pages (even if belonging to a previous Release). 4-13 - 001 00 5-41-00 4044 -00 00 5-12-00 Base SESE og ai 4-15 -00. 00 5-13 -00. = AWARNING . _ ‘4-16 -00. 00 5-14-90. failure to update the manual and to eliminate ; aad the obsolete pages makes it more difficult to con- aie 00 5-15 ‘sult the manual and may lead to the performance 4-18 -00. 00 5-16 -00 of incorrect operations on the vehicle, with serious 4-19 -00 00 5-17 -00 Consequences for the safety of the engine, of the || 4-20-00 00 8-18-00 ‘ehicle and of persons and property. | 4221-00 00 5-10-00 | 4-22-00 00. 5-20 -00 The manual consists of # 7 sections, for a total amount of 4-89 -00. 00 5-21 0 # 166 pages, as listed below. 4-24 -00 00 5-22 -00 4025 -00 00 $29 -00 NOTE For the nomenclature of the standard page of ae “op ecto std the manual (and spectically forthe defntion ofthe page 4725 0) or a4 umber) se@ 0.2 (HOW TO CONSULT THE MANUAL), 4727 “02 cies 4229 -00 ot 8-27 -00 4230 -00 01 8-28-00 0.1.2 UPDATED MANUAL GENERAL LIST cat 00 Ot 5-29-00 00 432 -00 01 5-80-00 00 pagt Release pag Release 4°92 oa 90 0-1 -00 01 2-16-00 00 434-00 or 8-32-00 00 0-2 -00 01 2-17 -0 14.35 -00 oY 8-83-00. 00 0.8 -00 01 2-18 -0 00 498-00 00 $34 -00 00 0-4 00 00 2-19 -0 00 4237-00 00-1 -00 00 0-5 -00 00 2-20 -0 004.38 -00 00 0-2 -00 01 0-6 -~ 00 3-1 -@ 00 4239-00 00 0-3 -00 01 0-7 -0 01 3-2 -o 00449 -00 00 0-4 -00 00 0-8 -@ 00 3-3 -@ 00 aay -00 00 0-9 -@ 00 3-4 -@ 00 asa 00. 00 0-10 -00 09 3.8 -@ 00. 4rag ao 00 121-00 00 3-6 -@ 00 4-44-00 0 122 +00 00 3-7 -@ 004-45 00 0 128 “a0 00 3.8 -@ 00446 -00 00 124 “00 00 3-9 - 00 447-00 00 128-00 00 3-10-00 00 aaa -00 00 128 -00 00 8-11 - 0 449-00 00 2o4 00 00 3-12 -0 00 480-00 00 2-2 00 00 8-10 -0 00 4251 -00 00 2:3 -0 01 3-14-00 00 4-82-00 00 2-4 +0 Ot 3-15 -0 00 4.83.00 00 2-5 -00 00. 3-16 -20 00 4-54.00 00 2-6 -00 00. 3-17 -2 00 4-85-00 01 2-7 -00 00 3-18-00 00 4.88.00 0 2-8 -00 00 3-19-00 ot 4-87 00 0 2-9 -00 00 8-20 -00 00 4-58-00 0 2-10-00 00 321-0 00 4259-00 00 2-11-00 00 3-22-00 01 4260-00 00 2-12-00 00 3-29-00 004.61 -a0 00 2-19 -00 01 8-24 -00 00 462-00 00 2-14 -00 00 3-25 -a co 468-00 00 2-18 -00 00 8-26 -0 00 4-64-00 00 Release 01/2001-10 = 3-00INTRODUCTION 990 engine 0.2 HOW TO CONSULT THE MANUAL 1 “Vo onaina a 4.3 BALL BEARINGS AND OIL SEALS INSTALLED ON THE ENGINE CRANKCASE ~ Matves Carey rad 0.5.1 (PRECAUTIONS AND GENERAL, INFORMATIONS) @ $1 rerome neous NOTE the ot seals con be dssstorbied and aser- ed witout romovr to eng Fam eves Gtr cca ‘coerce SE nin NOTE Arron esr os soe ea WORK ON THE INDIVIDUAL PARTS" 432 REMOVING THE BALL BEARINGS. “+ Unscrew and romeve the MG FH sows (4) secung thea beags ‘g Remove ha 18 nangsnead sew (9) ge caang oa amportre of aprox 80 006 Giena NOTE tn orcor'eavid camaging he gaat sta, Soraya ea Seema “ag et a Seas cer gereaee Ursetatatoon nner egy et us en an ‘gearshit seconcary shat (11), tywhe! side = is greater than < ‘equal to or less than 2 is equal to or greater than ~ approximately es = infinity °c = degrees Celsius (centigrade) °F = degrees Fahrenheit * plus or minus ac. = alternating current A ampere Ah = ampere per hour APL ‘American Petroleum Institute HV high voltage AVIDC = AntiVibration Double Countershatt bar = unit of pressure (1 bar = 100 kPa) dc. direct current cm cubic centimetres co = carbon monoxide CPU = Central Processing Unit DIN = German industrial normative (Deutsche Industrie Norm) DOHC — = Double Overhead Camshaft Ecu Engine Control Unit rpm revolutions per minute He tunbumt hydrocarbons Isc Idle speed control Iso = Intemational Standardization Organization kg kilograms kgm kilograms per metre (1 kgm = 10 Nm) km kilometres. km/h = kilometres an hour ka = kilo-ohms kPa = kiloPascal (1 kPa = 0.01 bar) ks clutch side (Kupplungseite) kw = Kilowatt ‘ litres LAP lap (race course) LeD Light Emitting LEFT SIDE —=left side ms metres an second MAX maximum mbar millbar (1mbar = 0.1 kPa) mi = mile MIN = minimum, MPH rmiles per hour Ms = flywheel side (Magnetoseite) ma megaohm NAL not Available (Not Available) N.O.M.M. = "Motor" method octane number N.O.R.M. = “Research” method octane number Nm = newton per meter (1 Nm = 0.1 kgm) a =ohm O-s-0 990 engine PICK-UP = pick-up BDC = bottom dead centre TDC = top dead centre PPC = Pneumatic Power Clutch RIGHT SIDE =right side SAE Society of Automotive Engineers TEST = diagnostics test T.B.EL. = convex socket head T.C.EI. = hexagonal socket head TE. =hex-head TP. flat head TS! Twin Spark ignition UPSIDE- DOWN = upside-down rods v volt w = watt ° diameter Release 00/2001-06INTRODUCTION 990 engine. NOTE O-9-0 Etc Release 00/2001-06INTRODUCTION 990 engine “ety L- 10-00v990 engine GENERAL INFORMATION 4 H-1-~ Release 00/2001-06GENERAL INFORMATION ¥990 engine GENERAL INFORMATION PoC A Doe) 4.4 POSITION OF THE SERIAL NUMBERS 1.1.1 ENGINE NUMBER ..... 1.2 INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENTS. ADA FUEL srr 1.2.2 ENGINE OIL 1.2.3 COOLANT 1.2.4 CARBON MONOXIDE. 1.2.5 HOT COMPONENTS ... 1.3 SPARE PARTS +2-00 158-00 1-3-0 . 18-00 . 1-3-00 4-8-00 . 1-4-0 1-4-0 . 1-4-00 1-4-0 Release 00/2001-06GENERAL INFORMATION 990 engine 1.4 POSITION OF THE SERIAL NUMBERS ‘These numbers are necessary for the registration of the vehicle. Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. 1.1.1 ENGINE NUMBER ‘The engine number is stamped on the rear part of the en- gine, near the pinion 1.2 INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENTS 1.2.1 FUEL can become explosive. Avoid any contact of the fuel with the skin and the in- halation of vapours; do not swallow fuel or pout from a receptacle into another by means of a tube. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. Use only premium grade unleaded petrol, min. O.N. 95 (N.O.R.M,) and 85 (N.O.M.M). 1.2.2 ENGINE OIL Engine oll may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. Do not dispose of the oil in the environment. Deliver it to or have it collected by the nearest oil sal- vage center or by the supplier. In case any maintenance operation has to be carried out, itis advisable to use latex gloves. For the maintenance intervals, see 0.4.1 (VEHICLE WORKSHOP MANUALS). For the lubricant types, see 2.2 (LUBRICANT CHART). Release 00/2001-06 -3-00GENERAL INFORMATION 990 engine 1.23 COOLANT The coolant is noxious: do not swallow it; if the cook ant gets in contact with the skin or the eyes, it can cause serious irritations. If the coolant gets in con- tact with your skin or eyes, rinse with plenty of water and consult a doctor. If it is swallowed, induce vomit, rinse mouth and throat with plenty of water and consult a doctor with- out delay. DO NOT DISPOSE OF THE FLUID IN THE ENVIRON- MENT. KEEP AWAY FROM CHILDREN. Be careful not to spill the coolant on the red-hot parts of the engine: it may catch fire and send out invisible In case any maintenance operation should be re- quired, itis advisable to use latex gloves. Do not use the vehicle ifthe coolant is below the min- imum prescribed level. For the maintenance intervals, see 0.4.1 (VEHICLE WORKSHOP MANUALS). For the lubricant types, see 2.2 (LUBRICANT CHART). NOTE The characteristics of the various antifreeze liq- Lids are different. Be sure to read the label on the product to lear the degree of protection it guarantees. Use only antifreeze and anticorrosive without nitrite in order to ensure protection at at least -35 °C. 1.2.4 CARBON MONOXIDE Ititis necessary to let the engine run in order to carry out ‘some work, make sure that the area in which you are op- erating is properly ventilated. Never run the engine in enclosed spaces. Ifitis necessary to work indoors, use an exhaust evacua- tion system. The exhaust fumes contain carbon monoxide, a poi sonous gas that can cause loss of consciousness and even death. 1.2.5 HOT COMPONENTS: ‘The engine and the components ofthe exhaust tem become very hot and remain hot for some after the engine has been stopped. Before handling these components, wear insulating gloves or wait until the engine and the exhaust sys- tem have cooled down. Eo 1.3 SPARE PARTS For any replacement, use aprilia Genuine Spare Parts only, see 0.4.2 (SPARE PARTS CATALOGUES). aprilia Genuine Spare Parts are high-quality parts, ex- Pressly designed and manufactured for april sult in incorrect performance and damages. Release 00/2001-06GENERAL INFORMATION 990 engine NOTE Vw, H-5-00 Release 00/2001-06GENERAL INFORMATION 990 engine NOTE Release 00/2001-06 H-6-00v990 engine TECHNICAL INFORMATION E Release 00/2001-06 ———___— EJ —_______ ]-1-~TECHNICAL INFORMATION v990 engine SERVICE AND SETTING UP PCR or 2.1 TECHNICAL SPECIFICATIONS .......... 2-3-00 2.2 LUBRICANT CHART .. 7 1 25-00 2.3 SPECIAL TOOLS Ul... nnsnnns 26-00 2.3.1 ENGINE TOOLS |... snes 28-00 2.3.2 MISCELLANEOUS TOOLS «enue 2-8-00 2.3.3 TOOLS USED FOR OTHER aprilia VEHICLES sensiinnnernnnne 210-00 2.4 CONSUMABLES ......... soe 214-00 2.4.1 PRODUCT PROPERTIES .. 2-11-00 2.4.2 USE OF CONSUMABLES 2-12-00 2.5 FASTENING ELEMENTS ........ . 2-14-00 2.5.1 JOINTS WITH CLICK CLAMPS AND SCREW CLAMPS... 2-14-00 2.5.2 GENERAL SPECIFICATIONS OF ‘THE DRIVING TORQUES sevns 215-00 2.5.3 DRIVING TORQUE «0 2-16-00 Release 00/2001-06v990 engine TECHNICAL INFORMATION 2.1 TECHNICAL SPECIFICATIONS ENGINE aes = Model v990 Type 60° longiucinal V-type, wo-cyinder, stroke, with 4 valves per cylinder, DOHC. Number of cylinders 2 Total displacement KEIN GEIB (‘98 -'99- 2000 models) KM [997.6 om [Total displacement ISMN GEIB (models starting trom 2001) 998 om? [Total displacement __ [997.62 om? Max. rated power (to driving shaft) - [86.5 kW (118 HP) at 9250 rpm Max. rated power (to driving shaft) KEM [70 kW (94 HP) at 9250 rpm [Max. rated power (to driving shatt) [77 kW (104 HP) at 9250 rpm Max. torque 196.5 Nm (9.65 kgm) at 7250 rpm Max. torque KE ED [82 Nm (8.2 kgm) at 7000 rpm Max. torque I '90 Nm (9.0 kgm) at 7000 rpm Bora/stroke (97 mm/67.5 mm [Compression ratio KEN [ias05:4 [Compression ratio 11.8205:4 [Compression ratio KN 10420534 [Average piston speed [22.5 mis at 10000 rpm 2001) [Camshaft during intake stroke KEIN EBB ‘98 — "99-2000 mod- |262°, valve liing= 10.60 mm els) [Camshaft during intake stroke KEIN IBID (models starting from 262°, valve liting= 11.40 mm [Camshaft during intake stroke KEN 259°, valve lifting= 10.60 mm [Camshaft during intake stroke KE 242°, valve liting= 9.50 mm [Camshaft during exhaust stroke KM) iM IE 259°, valve lifting= 10.60 mm [Camshaft during exhaust stroke 242°, valve lifting= 9.50 mm Valve advance (with valve clearance 1mm) KE [5 Si fopening during intake stroke = 20° before TDC ‘elosing during intake stroke = 62 after BDC. ‘opening during exhaust stroke = 64° before TDC ‘closing during exhaust stroke = 15° after BDC Valve advance (with valve clearance 1 mm) KE 5 HES (models starting from 2001) ‘opening during intake stroke = 25° before TDC [closing during intake stroke = 59° after BDC. opening during exhaust stroke = 65° before TDC closing during exhaust stroke = 15° after BDC \Vaive advance (with valve clearance 1mm) EEE lopening during intake stroke = 20° before TDC jclosing during intake stroke = 59° after BDC Jopening during exhaust stroke = 64° before TOC [closing during exhaust stroke = 15° after BDC Valve advance (with valve clearance 1mm) lopening during intake stroke = 25° before TDC closing during intake stroke = 37° after BDC. fopening during exhaust stroke = 57° before TDC closing during exhaust stroke = 5° after BDC Valve clearance during intake stroke (0.12 - 0.17 mm Valve clearance during exhaust stroke (0.23 - 0.28 mm Diameter of the inlet valve plate 36.0 mm. Diameter of the exhaust valve plate 31.0 mm [Engine revolutions at minimum rpm EN A [1250 = 100 mpm ly Engine revolutions at minimum rpm I 1200 + 100 rpm [Engine revolutions at peak pm KEM I ES 10250 = 100 rpm [# Engine revolutions at peak rpm I 10500 = 100 rpm # Engine revolutions at peak rpm 19000 = 100 rpm Ignition ‘electronically controlled {starting electric Release 01/2001-10 Fatow > B-3-0TECHNICAL INFORMATION ‘Spark advance v990 engine [At start: 5° before TDC, additional advance depending ‘on specific consumption levels ‘Starter motor gear ratio 19/9 * 30/11 * 64/30 = 31.677 Clutch multidisc in oll bath, with hydraulic control on the left side of the handlebar and PPC device -# 9 friction dises; thick 3.5 mm -# 10 steel discs; thick 1.5 mm [Transmission Mechanical, 6 gears with foot control on the left side of the engine Lubrication system lary pan with separate oil tank, # 2 trochoidal pumps| land cooling radiator Lubrication pressure min 500 kPa (5 bar) lat max 80 °C (176 “F) and 6000 rpm [Air cleaner with dry fier cartridge Cooling liquid-cooled [Coolant pump gear ratio igg= 26/27 * 26/28 = 1.037 Coolant pump delivery (with thermal expansion valve open) '90 Z/min and 9000 ppm ‘Thermal expansion valve opening start temperature 65 = 2°C (149.5 °F) Engine dry weight ~ 65 67 kg Final ratio Total ratio. 17/42 = 1:2.470 11.948 # sprocket teeth GEAR RATIOS Total ratio 16/41 = 1: 2.563 12.399 8.679 6.787 Batt Arad 4.205 [# sprocket teeth (GEAR RATIOS. Prima * 31160 = 14.935 ‘Secondary Final ratio Total ratio. 1485 =1:2.50 16/431: 2.687 13.00 16928 = 1: 1.750 9.102 i TAIT 5.674 4.975 4.431 # sprocket teeth inal ratio Total ratio 17/45 = 1 : 2.647 12.804 9.041 7.008 5.582 4.898 4.358 # sprocket teeth Foon Release 01/2001-10INICAL INFORMATION va00' TECHNIC, fo [Type [Choke a [Choke Kil indirect injection (MULTIPOINT) a premium grade unleaded petrol, min. O.N. 95| (N.O.R.M,) and 85 (N.O.M.M).. [Standard INGK R DCPR9E. [Spark plug gap [0.6 -0.7 mm Resistance 5 KO [Generator (with permanent magnet) KE i A KEE [12 V — 400 W (850 W for models [Generator (with permanent magnet) Kil 12 V—470 W Starter 12 V0.9 kW [Starter motor gear ratio 49/9" 30/11" 64/30 = 31.677 2.2 LUBRICANT CHART Engine oil (recommended): EE EXTRA RAID 4, SAE 15W - 50 or SRAgip TEC 4T SAE 15W - 50. ‘As an alternative to the recommended ol its possible to use high-quality ols with characteristics in compliance with or superior to the COMC G-4, API. SG specifications. ‘Bearings and other lubrication points (recommended): EE] Bimol Grease 481, EE AUTOGREASE MP or Agip GREASE 30. {As an altemative to the recommended product, use high-quality grease for rolling bearings, working temperature range -30 °C...+140°C, ‘ripping point 150 °C...230 °C, high protection against corrosion, good resistance to water and oxidation, Use new clutch fluid only. Clutch fluid (recommended): EZ] F.F., DOT 5 (DOT 4 compatible) or Agip BRAKE 5.1, DOT 5 (DOT 4 compatible). Use only antifreeze and anticorrosive without nitrite, ensuring protection at-25 °C atleast. Engine coolant (recommended): EE ECOBLU -40 °C or fRAgip COOL. Release 00/2001-06